Colored Coding System For Packaging Materials

ABSTRACT

A color-coded packaging system is provided where a set of different colors are selected with each color designated to signify a varying feature of a product such as a dimensions of a pouch for receiving instruments for sterilization. Printed information or indicia printed on that pouch are printed in a colored ink designating the size of that pouch. Multiple pouches of the same size are packaged in boxes which have information or indicia printed thereon in the same color so that the size of box contents can be readily determined by the color of the printing thereon. The storage area can also include designated color coded areas for placement of like colored boxes. The color coding of the storage area, the boxes and the content of boxes provides for easy selection of a desired product as a means for a quick visual inventory.

The present disclosure is directed to a system for storing multiplesamples of various products, all of which have a feature or functionwhich is similar but which each have at least one feature that isdifferent, such as size. The system includes indicia on the product orthe product packaging for readily identifying the nature of the productor that different feature or function of each of the stored productsfrom a distance. More particularly, all of the packages having the samefeature, and all of the containers holding the multiple packages withthe same feature will have, in a readily visible location, a colored orother type of indicia printed thereon that is correlated to the variablefeature. More specifically, in one intended use of the system, pouchesused for packaging medical instruments are color coded. A user familiarwith the color codes, upon viewing a pouch or a storage shelf containingmultiple different size pouches, can readily locate a pouch of aspecific size, or for a specific use, or fabricated from a specificmaterial and then select the desired pouch for an intended purposesolely by viewing the one or more colors printed on the pouch or boxesof pouches.

BACKGROUND

Numerous medical instruments are sterilized and reused. Theseinstruments are typically cleaned, inserted into a sealable pouch andthen sterilized. In dental offices for example, instruments are gatheredafter use, cleaned, and packaged in sterilizable pouches. The pouchesare then sealed and subjected to a sterilizing environment such as anautoclave wherein steam or high temperature water vapor is used tosterilize the instruments. Alternatively, the pouch-enclosed instrumentscan be subjected to other sterilization techniques such as a sterilizinggas, for example, ethylene oxide, or exposure to radiation or UV light.The instruments are then stored in the sealed pouches for later use.

Typical sterilizing pouches are formed of two layers of sheet materialsprinted with identifying brand names and other information on an outwardface. These pouches are available in numerous different widths andlengths and may also have different internal volumes by being formedwith pleats or gussets. Still further, the pouch may be formed fromfront and back sheets of a paper or plastic material where at least onsheet or portion thereof is permeable to the sterilant but the sealedpouch is impermeable to bacterial or other contaminants. Examples ofsuitable materials are cellulosic papers, sheets formed from plasticfibers or fibrillated plastics, such as TYVEK® or clear imperviousplastic films.

In typical embodiments, the pouch comprises first and second sheetmaterial walls, the periphery of the walls being joined to define thepouch. One of the sheet material walls is preferably transparent andwater vapor impervious, and one of said walls is preferably cellulosicand water vapor and sterilization gas pervious. The joinder of the wallsdefines a perimetrical seal about a partially closed volume within whichthe instruments are placed for sterilization. The pouch can also have aflap on one of the walls arranged to overlie the other of the walls insealed relation to fully enclose the volume. Typically the two sheetsare joined by heat sealing. However, if the pouch includes the flap amedically acceptable adhesive, which is unaffected by the sterilizationprocess, can be applied to the flap so that the pouch seals are providedby both heat sealing and adhesives.

Multiple pouches (for example 100, 200, 500 etc.) of the same size areprovided in a shelf pack or box. The user will typically order multipleshelf packages of the same size pouch as well as multiple packages ofthe other available sizes of pouches. For example, the user may purchaseseveral packages of each of the 8-12 different sized pouches that may beavailable. This means that a working supply of pouches may comprise50-100 boxes, each box containing 100 or more of a specific size. Whenthese are all stored stacked on shelving it can be difficult to readilylocate the desired size pouch for use in packaging the instruments andit may be necessary to handle multiple boxes and read the label on theface of the box to determine its contents. Further, while theidentification of the contents of the box may be printed on the endflap, which is visible when stacked, to allow easy access to thecontents of the box the end flap is typically removed from the box or atleast folded out of view. To further add to the problem of locating thecorrect pouches, a further set of pouches may have a different use. Forexample they may be constricted of materials particularly chosen forautoclaving, ethylene oxide sterilization or other sterilizationtechniques such as radiation or UV exposure. Still further, in afacility with multiple physicians or different departments (i.e.,surgery, radiology, pediatrics, etc.) each physician or each departmentmay desire that their supply of pouches is segregated. This requiresseparate storage arrangements or some means to distinguish the variousdifferent pouch inventories.

Accordingly, there is a need for an easy means to segregate, label,discriminate and select similar products which have at least onefeature, characteristic or function which is different when thosesimilar products are all stored in the same storage area.

SUMMARY

A color-coded packaging system is provided where a set of differentcolors are selected with each color designated to signify a varyingfeature. For example, pouches for packaging instruments forsterilization are available in different sizes to accommodate differentsized contents. A specific color is assigned to each sized pouch andinformation and indicia printed on that pouch is printed in a coloredink designating the size of that pouch. Multiple pouches of the samesize are packaged in boxes which have information or indicia printedthereon in the same color so that the size of box contents can bereadily determined by the color of the printing thereon. Both the pouchand the box can also have printing in a second color, selected from asecond color coding system, to designate a second feature of the pouch.The storage area can also include designated color coded areas forplacement of like colored boxes. The color coding of the storage area,the boxes and the content of boxes provides for easy selection of adesired product as a means for a quick visual inventory.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be further described as to an illustrativeembodiments in conjunction with the attached drawings in which:

FIG. 1 is a top view of a representative first embodiment pouchincorporating features of the invention.

FIG. 2 is a sectional view thereof taken along line 2-2 in FIG. 1.

FIG. 3 is a perspective of a representative box containing multiplepouches, as shown in FIG. 1, all having the same characteristic orfeature.

FIG. 4 is a front view of multiple boxes, each box containing pouches,on a storage rack incorporating features of the invention.

FIG. 5 is a view of a first embodiment of a box end flap incorporatingfeatures of the invention.

FIG. 6 is a view of a second embodiment of a box end flap incorporatingfeatures of the invention.

FIG. 7 is a top view of a second embodiment of a pouch incorporatingfeatures of the invention.

DETAILED DESCRIPTION

FIGS. 1 and 2 show a typical pouch 10 incorporating features of theinvention. In a preferred embodiment the pouch 10 comprises a first orlower sheet 12, typically a planar sheet material, of a suitableprintable barrier material, such as a printable cellulosic medical gradepaper which is impermeable to external contaminants, will not decomposeunder sterilization conditions, and is pervious to steam, water vaporand sterilization gases. A second or upper sheet 14 is a planar sheet,also impermeable to external contaminants and will not decompose understerilization conditions, but is impervious to water vapor, steam andtypical sterilizing gases. It is typically a transparent plastic such aspolyester, or a polyester/polyolefin laminate. The second sheet overliesthe first sheet and is heat sealed thereto along three sides to form aperimeter seal line 16 created a pouch with an open end 18 to form thepouch 10. The opposite end, also referred to as the lower end 34 of thepouch 10, is closed. Following insertion of an instrument into the pouchthe open end 18 is closed. One alternative means of sealing is to foldover a flap 20, which is part of the lower sheet 12 and is coated withan adhesive, and attach the flap to the upper sheet 14. Attachment maybe provided by a contact adhesive 22 which is pre-applied to the flapand is covered by a removable piece of release paper (not shown). Analternative is to use heat sealing techniques, which are known in theart, to seal the upper sheet 14 to the lower sheet 12 thus sealing theinstrument within the pouch 10.

Printed on the first sheet 12 in various locations 24, 26, 28, which maybe visible through the transparent second sheet 14 or alternativelyprinted on the lower surface of the first sheet, are various differentpieces of information such as the manufacturer's name, trademark,various certification marks, a specified use of the pouch or itsintended contents and the pouch product code, dimensions and othercharacteristics. The printing locations identified in FIGS. 1, 3 and 7are merely representative and are not intended to limit the location ofthe information or the purpose of the printed information. A feature ofthe invention is that some or all of the printing on the pouch is in acolor, in accordance with an established color code system, that is usedto designate the size of the pouch. As an example Table 1 lists 12different pouch sizes and the colors, referred to as a first color 30,chosen to represent the various pouch sizes.

POUCH SIZE COLOR width × length (inches) (PANTONE COLORS)  3.5 × 5.25RED (PMS 185) 2.75 × 9.0  GREEN (PMS 3415) 3.5 × 9.0 ORANGE (PMS 144)2.25 × 4.0  SILVER (PMS 5497) 5.25 × 6.5  BLUE (PMS 293)  8.5 × 15.0PINK (PMS 212) 3.25 × 12.0 PURPLE (PMS 258 4.25 × 12.0 GOLD (PMS 118) 8.0 × 12.0 BLACK 5.25 × 12.0 BROWN (PMS 469) 10.5 × 16.0 BABY BLUE (PMS283) 13.25 × 20.0  FOREST GREEN (PMS3435)

The color coding allows one familiar with the coding system, uponviewing the colored printing on the first or lower sheet 12, toimmediately know the size of the pouch. For example if the first color30 used for the printing is red the pouch is 3.5″×5.25″. As an addedfeature, the first color 30 is also applied on the first sheet at thecorners 32 of the initially sealed lower end 34 of the pouch so that itcan be observed by viewing the initially sealed lower end 34 of thepouch 10. Colored left and right rectangles 36, 38 on the pouch sealedend are merely representative locations and other locations orcombinations of locations on the sealed lower end 34, such as a solidstripe or a series of rectangles across the lower end of the pouch 10can be utilized. The purpose of this feature is explained below.

FIG. 3 shows a box 40 with the end flaps 60 removed. The box 40 containsmultiple pouches 10 all of the same size and therefore all having thesame color print which also matches the color of the left and rightrectangular areas 36, 38. The box 40 shown in FIG. 3 also has at least afirst and second area 42, 44 printed in the same color as on the pouch10. For example, if the box contains 2.75 in×9.0 in pouches the firstcolor 30 is green and the printing on each pouch 10, the left and rightrectangles 36, 38, and the first and second areas 42, 44 on the box 40are all the same color green. Even though the colored printing on theleft and right rectangles 36, 38 is applied to the top of the lowersheet 12, it tends to penetrate the material of the first sheet as wellas the exposed end of the lower sheet 12 at the initially sealed lowerend 34 of the pouch 10. Therefore, even when the pouches 10 are stackedin the box 40 an individual viewing the open end of the box can see thecolor of the left and right rectangles 36, 38. In addition, the ends ofthe pouches tend to curl slightly downward, further allowing the colorindicia thereon to be seen. In a preferred embodiment the inner endflaps (not shown) of the box as well as the end flap 60 are alsopartially or filly colored with the same first color 30. The first andsecond areas 42, 44 on the box 40 as shown in FIG. 3 are onlyrepresentative locations for the location of the first color 30 on thebox 40 and other locations or larger or smaller areas on any of theouter surfaces of the box may be colored with the first color 30. Theouter surface of the box can also display a second color 50 which is acolor within a second color coding system to designate a further ordifferent feature of the contents of the box. While it is preferred thatthe second colors 50 from a second coloring system are different fromthe first color 30 they may be selected from the same set of colors.Confusion is minimized or eliminated because an individual, uponobserving the box, recognizes that, because of its specific location onthe box, it represents the second feature. In the present example, wherethe first color 30 identifies the size of the pouch in the box thesecond color may, for example, represent a characteristic of thepackaging material, a physician user within a group of physicians or adepartment (i.e., radiology, emergency room, pediatrics, etc.) within amedical facility. One skilled in the art will recognize that the outersurface of the box can include many different pieces of informationincluding, but not limited to the manufacturer's name, address,trademarks, product description, instructions for use, usage warnings,etc. which may be printed in the first color 30, a complementing coloror a second color 50. In addition, black or white may be used as eithera first color 30, a second color 50, or limited to use for printingwhich may have no meaning in the color coding or could designate a stillfurther two color code.

FIG. 4 shows multiple different sized packages stored in a singlestorage cabinet 52 and illustrates the utility of the color codingsystem to aid in selecting individual desired products, for example aparticular sized pouch 10, from multiple boxes 40 of the different sizedpouches 10. Stored and displayed in cabinet 52 are nine different sizepouches 10, the location for a tenth size pouch 10 being empty. In theillustrated example the cabinet 52 contains thirty-one boxes 40 ofpouches 10 some of which are open (have the end flap removed) whileothers are unopened. A first stack 54 of boxes 40 contains three closedboxes 40 with a partially filled open box 40 on the top of the stack 54.The first color 30, indicated in this case by the indicia 30 a,signifying the dimensions of the pouches 10 in each box 40, is the sameas shown on the visible end flap 60 of the three closed boxes 40. Thecolor code 30 a on the left and right rectangles 36, 38 on the pouches10 in the open box 30 is also visible. Each of the stacks of boxes 40contains different sized pouches 10 and therefore, to indicate the firstcolor 30 in each instance is different, the indicia for the 9 differentstacks of boxes is indicated as 30 a through 30 j. As an added feature,a label 56 is placed on the front of the shelf 58 below each stack, thatlabel 56 being colored to match the stack of boxes designated for thatlocation (i.e., the label on the shelf 58 below the first stack 54 bearsthe first color 30a which matches the first color 30 on the boxes andpouches stacked above. This allows a user to quickly identify, becauseof the open space on the lower shelf 58, that all of the pouches 10 of asize designated by the first color 30h have been used up and it is timeto replenish the inventory of that size.

Further, if the packaging includes a second series of color coding(i.e., the second color 50) that color can also appear on the end flap60. FIGS. 5 and 6 show different examples of the end flap 60 which canhave one or more colors for the one or more color coding systems. InFIG. 5 the top of the end flap 60 displays the first color 30 and thelower half can be blank (white) or display a second color 50. Theprinted lettering 62 can be a third color, or black or white todesignate a third feature or to merely provide information to the user.

FIG. 7 shows a second embodiment of the pouch 10 also displaying asecond color 50 on the visible end of the pouch 10.

While the coded packaging system has been illustrated by the use ofdifferent colors to designate different sized products packaged insimilar types of boxes 40 the system can also utilize other designationsystems such as shades of grey or different types of colored or blackand white cross hatching. Also, while a specific color, for examplegreen, may be used to designate a specific size product, differentshades of that color (light green, forest green, etc.) can be used todesignate other features or characteristics of the product. For example,in the coding system set forth above brown designates a 5.25×12.0 pouch.A dark, chocolate brown could designate a flat pouch and a light brownor tan could designate the same size pouch with pleats or gussets andthus expandable to hold a greater volume. Also while the preferredembodiment designates a pouch of a particular length and width, a firstcolor can be used to designate a length and a second color can designatea width. As a still further alternative a set of colors could designatea series of dimensions (a different color for each of 1 inch, 2 inch, 3inch, etc.) and then the same color code could be used to designate thedimensions for both the length and width. For example if red designatesa 3 inch dimension and green designates a 6 inch dimension a red/greencombination would designate a 3×6 pouch, a green/red combination woulddesignate a 6×3 pouch and a green/green combination would designate a6×6 pouch.

1. A color coded packaging system comprising multiple duplicate products stored in single box, the multiple duplicate products being supplied in various different sizes, wherein each product of the same size includes on a visible surface thereof a specific color representative of a feature of that product, the specific color also being prominently displayed on the box so that the contents of the box can be determined by observing the color on the box said color being one of the colors in a color coding system, each color in the color coding system designating a specific variable feature of the contents of the box.
 2. The color coded packaging system of claim 1 wherein a feature of the contents of the box, following removal of a portion of the box to expose a portion of the contents thereof, can be determined by observing a color within the color coding system visible on one or more of the contents.
 3. A method for recognition of the size of a disposable pouch without reading a printed size description or measuring the pouch wherein pouches are available in multiple sizes and each of the multiple sized pouches comprises at least one surface formed from a sheet of a printable material comprising: establishing a color coding system comprising multiple different colors whereby a particular color or shade of color is designated to represent a specific sized pouch, and using ink of the particular color or shade designated to represent a specific sized pouch, information or indicia is printed on the printable material surface of said pouch.
 4. The method of claim 3 wherein said printing includes as a minimum and indicia printed on an end of the printable material, said indicia observable when an edge of the end of the pouch is viewed.
 5. The method of claim 4 wherein multiple pouches of the same size are packaged in a box and said box has information or indicia printed thereon regarding the contents of said box, at least some of said information or indicia is printed using a colored ink selected from the color coding system that matches the color ink used to print the information or indicia on the pouch packaged therein.
 6. The method of claim 5 wherein multiple boxes of different sized pouches are placed in a storage area, each box containing only one size of pouches, the printed information or indicia on each box having a color selected from the color coding system designating the content of that specific box, the different print colors on the boxes being visible by an observer.
 7. The method of claim 6 wherein boxes of the same sized pouch are stacked together on a shelf such that each of the boxes having the same colored printing are located together, the inventory of different sized pouches being determinable by observing the different printing colors on the boxes and the color of the indicia on the end of the pouch when a box is open to display the contents thereof.
 8. The method of claim 5 wherein, upon opening and end flap on a box or removing end flaps on a box reveals the contents of the box and the color of the indicia on the end of the pouch is observable.
 9. A color coded packaging system for labeling various differently dimensioned pouches so that an observer can distinguish between the various different sized pouches by observing a color printed thereon, said color being one of multiple colors in a color coding system, each color in the color coding system designating one or more specific dimensions of the pouch, comprising: a packaging system comprising multiple different sized pouches and multiple different sized boxes, each of the different sized boxes containing multiple same-sized pouches wherein each pouch of the same size includes on a visible surface thereof a specific color representative of one or more dimensions of that pouch, said specific color selected from the color coding system, that specific color also being displayed in a visible location on the box containing multiple same sized pouches so that the contents of each box can be determined by observing the color displayed on the box.
 10. The color coded packaging system of claim 9 wherein the specific color is printed on an end flap of the box.
 11. The color coded packaging system of claim 10 wherein the specific color is also printed and on one or more sides of said box.
 12. The color coded packaging system of claim 11 wherein the specific color printed on at least one location on each of the pouches within a box is visible to an observer when the end flap of the box is open or removed.
 13. The color coded packaging system of claim 12 wherein the at least one location on each of the pouches comprises at least a portion of an end of each pouch in the box visible when the end flap of the box is open or removed.
 14. The color coded packaging system of claim 9 wherein the pouches are provided in at least about eleven different sizes and the color coding system comprises at least eleven different colors or shades of color. 